engine block repair Archives - Connecting Rod Repair

Lock and Stitch Cast Iron Repair | Metal Surgery | Cracked Engine Block Repair | Repair Cracked Cast Aluminum

RA Power Solutions undertakes the repair of crack or damaged engine components manufactured out of cast steel, repair cracked cast aluminum, cast iron, or aluminum. We follow the process of Metal Stitching & Metal Locking for repair of crack or damaged components. In most cases, the repairs are undertaken on-site without dismantling the major components. This results in the saving of downtime of the plant & money.

Metal Stitching | Metal Locking

RA Power Solutions is a leader in this field of repair of large damaged casting components by Metal stitching & Metal Locking, we offer crack repair services 24/7 through our technicians who are well experienced. Our senior-most technician executing crack repair by metal locking and metal stitching process has 44 years of experience and has a record of executing more than 1500 jobs which are saved from rejection and are performing satisfactorily.

The repair of Crack and damaged casting by Metal Locking & Metal Stitching process

RA Power Solutions was developed in late 1930 as a cold option for repair of Crack or damaged cast iron components & equipment. This process of casting crack repair has proved successful as it is cold and stress-free without the generation of any heat. Most of the crack repair jobs undertaken by us, it does not require machining. Our technicians have Indian CDC / Palau CDC which facilitates them to execute the Crack repair even while sailing the vessel this again proves to be of great advantage to the ship owners and the industries.

The author is Mr. Raj Shahani Managing Director of RA Power Solutions having experience of almost four decades of working on high-capacity diesel engines, turbines, and rotary equipment. The company specializes in executing the repairs i.e. metal stitching/metal locking, grinding and repair of crankshafts, rebabbitting of bearings, Cast Iron Repair, connecting rod reconditioning, overhauling of Engines which have serious problems resulting in the immense saving to the owners.

For more information about metal surgery, engine block repair, metal surgery process, cold metal repair, cast iron stitching, cast iron engine block repair, or broken engine block, engine connecting rods please email us at rajshahani@rapowersolutions.com or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

RA Power Solutions undertakes the repair of crack or damaged engine components manufactured out of cast steel, repair cracked cast aluminum, cast iron, or aluminum. We follow the process of Metal Stitching & Metal Locking for repair of crack or damaged components. In most cases, the repairs are undertaken on-site without dismantling the major components. … Continue reading “Lock and Stitch Cast Iron Repair | Metal Surgery | Cracked Engine Block Repair | Repair Cracked Cast Aluminum”

Thread Repair Insert | Crack Repair Engine Block Cover | Onsite Machining – RA Power Solutions

Wartsila 12V32 Engine Block Repair via Onsite Machining

RA Power repairs threads and cracks damaged in accidents. The advantages are:

Conducted Magnetic Particle Inspection (MPI) across the engine block using Level 3 certified technicians to detect cracks.
Performed dimensional measurement of main journal housings to assess taper and ovality.
We carry portable, lightweight machines to the site to repair damaged threads.
The team cut out the damaged block portion completely.
Fabricated a new casting section matching the original Wartsila 12V32 block profile.
Installed the new section using metal stitching and metal locking techniques.
Finalized with onsite machining to restore main journal housing bore dimensions within manufacturer specifications.

Engine Block Repair | Onsite Machining | Crack Repair

Serving the diesel power plants and shipping companies for the last four decades, we observed that in spite of the best maintenance protocols and process followed, accidents do take place. We have the history of repairing seriously damaged engine blocks.

Recently, a Wartsila engine suffered heavy damage on both sides of the block measuring 600 mm × 500 mm. The accident also damaged the main journal housings. A barge with six Wartsila 12V32 units housed the engine.

Why RA Power Solutions Is Your Go-To for Engine Casting Repairs?

Four decades of industry experience, serving diesel power plants and marine clients.
Highly skilled teams capable of delivering on-the-spot repairs, minimizing plant disruptions.
Our methods sidestep destructive heat-based procedures, offering cold, stress-free solutions.
We’ve helped salvage thousands of components through repair methods that avoid needless replacements

For more information on Crack Repair for Engine Block, Thread Repair, contact us at rajshahani@rapowersolutions.com or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

FAQs:

1. Can a cracked engine block be repaired?

Yes, it can be repaired using metal stitching and onsite machining.

2. Is welding safe for engine block crack repair?

No, welding often causes heat stress—metal stitching is safer.

3. How much does engine block crack repair cost?

It’s far more affordable than replacing the entire engine block.

4. Can engine block cracks be fixed without dismantling?

Yes, portable tools allow onsite repair without removal.

When accidents strike—despite the strictest maintenance—threads on engine blocks, turbine casings, and cam blocks often suffer damage, frequently accompanied by cracks around the threaded areas. RA Power Solutions has developed a robust, onsite repair process that restores functionality without dismantling the components. Wartsila 12V32 Engine Block Repair via Onsite Machining RA Power repairs threads and … Continue reading “Thread Repair Insert | Crack Repair Engine Block Cover | Onsite Machining – RA Power Solutions”

Metal Stitching | Metal Locking | Repair of Cast Iron by Metal Stitching – RA Power Solutions

When cast-iron or aluminum engine blocks crack, the traditional fix—welding—is often expensive, risky, and destructive. At RA Power Solutions, we specialize in advanced cold repair techniques—metal stitching and metal locking—that restore structural strength without applying heat, requiring machining, or dismantling equipment.

With the improvement in repair technology now, it is possible to repair the crack in cast iron, steel, or aluminium component by metal stitching and metal locking process. The main feature of repair of crack or damaged casting by metal stitching, metal locking, and metal surgery is that process does not require disassembly of the equipment and taking the crack or damaged part to the workshop.

What Are Metal Stitching & Locking?

Metal Stitching is a precise, cold repair method. Technicians drill a series of aligned holes across the crack, insert metal “keys” or studs into a dovetailed pattern, and tighten them so they interlock—effectively sealing the fracture and restoring rigidity.
Metal Locking reinforces the stitching with custom-shaped metal inserts that prevent the crack from spreading further and enhance the repair’s long-term durability

New Casting Inserted for Repair of Engine Block

RA Power Solutions has the team of experience technicians. They can travel to the site with tools and consumables required for metal stitching and metal locking undertake the repair.We repair cracks by metal locking and metal stitching while maintaining the original profile. In most cases, the process does not require any machining. Scientific tests prove that the repaired crack portion has greater tensile strength than before.

RA Power Solutions with the experience of forty five years in this field extends metal locking and metal stitching services for repair of damaged casting. We can also execute the repair while the vessel is sailing. We offer the lowest cost compared to our competitors.

Metal Stitching | Repair Cast Iron | Cast Iron Repair

Get your crack or broken components manufactured out of cast iron, cast steel or aluminium repair by metal stitching and metal locking process. RA Power Solutions with experience of more than four decades have successfully repaired thousands of major engine components and components installed in heavy industries all over the world.

The damage to the component may be serious, or the cracks are multiple. RA Power Solutions engineers have the experience, know how and necessary tooling to execute the most complicated and serious damage which takes place due to accidents in cast iron, cast steel and aluminium casting.

For more information on cold metal stitching engine block, cast iron engine block repair, metal stitching surgery, metal stitching engine block, repair cast iron, and metal stitching of engine block please email us at rajshahani@rapowersolutions.com or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

Metal Stitching & Metal Locking of Engine Block Under Process

Metal Stitching of Engine Block by Special Keys & Locks

FAQs:

1. What are metal stitching and metal locking?

Metal stitching involves drilling a series of aligned holes across a crack, inserting interlocking metal keys or studs, and tightening them to seal the fracture. Metal locking uses custom-shaped inserts that reinforce and prevent crack propagation.

2. Do these methods require dismantling the equipment?

No. We perform the repairs in situ, without disassembling the machinery or removing the damaged part from its position

3. Will the original surface or shape be affected by the repair?

We maintain the original profile after metal stitching and locking, and in most cases, no machining is needed afterward

4. Is the repaired area as strong as the original component?

Yes. Scientific studies show that crack areas repaired by metal stitching and locking often have greater tensile strength than before

5. Can repairs be performed while the vessel is underway?

Absolutely. We can execute repairs while the vessel is sailing, minimizing downtime and logistical challenges

When cast-iron or aluminum engine blocks crack, the traditional fix—welding—is often expensive, risky, and destructive. At RA Power Solutions, we specialize in advanced cold repair techniques—metal stitching and metal locking—that restore structural strength without applying heat, requiring machining, or dismantling equipment. With the improvement in repair technology now, it is possible to repair the crack … Continue reading “Metal Stitching | Metal Locking | Repair of Cast Iron by Metal Stitching – RA Power Solutions”

Connecting Rod Repair | Reconditioning of Connecting Rod – RA Power Solutions

At RA Power Solutions, we specialize in precision reconditioning and repair of connecting rods for high-capacity marine, power plant, and industrial diesel engines. With over four decades of experience, our in-house services ensure performance restoration, cost efficiency, and uncompromising safety.

Reconditioned Connecting Rods of MAK Engine in Stock

Why Reconditioning Matters

Connecting rods face immense stresses—from piston movement and combustion forces to high RPMs. Over time, this leads to:

Taper and ovality in both big and small end bores
Misalignment and bent structures
Fatigue damage to serrations, bolts, or bushes

We do not recommend repairing a connecting rod if we find any loss of alignment or cracks. RA Power Solutions guarantees the satisfactory performance of every connecting rod we repair. We issue a calibration certificate for each connecting rod after repair.

Reconditioned Connecting Rod of Allen Engine in Stock

Built to Deliver Value:

Benefit	What It Means for You
Cost Savings	Reconditioned rods cost typically 25–33% of new OEM parts
OEM-Grade Quality	Repairs done to original specifications ensure reliable performance
Fast Turnaround	In-house facility and on-site services cut downtime dramatically
Global Reach	We export reconditioned rods globally—from ship yards to power plants
Trusted Guarantee	Performance-backed by certification and meticulous quality control

Who We Serve:

We export connecting rod of engines like Ruston, Allen, B&W, DAIHATSU, MAN, Mirrlees Blackstone, Niigata, Caterpillar, Deutz, Wartsila, Sulzer, Yanmar, Bergen, Mitsubishi, Cummins, etc.

For more information on connecting rod reconditioning services, maintenance and repair services, engine block repair, and connecting rod replacement, please email us at rajshahani@rapowersolutions.com or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

Reconditioning of Connecting Rod is in Process

Connecting Rod of Yanmar Engine Ready for Inspection Before Reconditioning

FAQs:

1. How do I know when a connecting rod needs reconditioning?

Look out for engine noise, vibration, oil contamination, or routine inspection findings like ovality or taper in rod bores.

2. Can every connecting rod be repaired?

No—if the rod is bent or has significant cracks, especially near the bolts or serrations, replacement is safer than reconditioning.

3. What types of engines can you service?

We support a wide range—including MAN, B&W, Wartsila, MAK, Deutz, Daihatsu, Yanmar, Mitsubishi, Caterpillar, and many others.

4. How much cost savings can I expect?

Reconditioned rods usually cost 60–70% less than new OEM replacements.

5. Are your services available globally?

Yes—our onsite crankshaft repair and inspection teams operate worldwide, offering rapid response and minimizing downtime.

At RA Power Solutions, we specialize in precision reconditioning and repair of connecting rods for high-capacity marine, power plant, and industrial diesel engines. With over four decades of experience, our in-house services ensure performance restoration, cost efficiency, and uncompromising safety. Why Reconditioning Matters Connecting rods face immense stresses—from piston movement and combustion forces to high … Continue reading “Connecting Rod Repair | Reconditioning of Connecting Rod – RA Power Solutions”

Connecting Rod Inspection – A Critical Step in Engine Overhaul By RA Power Solutions

The connecting rod is an important component of engine operation. It connects the piston to the crankshaft, converting the piston’s linear action into rotational motion. Over time and with continuous engine use, the connecting rod experiences high amounts of tension and wear. This makes routine inspection and maintenance of the connecting rod essential to ensure engine reliability and performance.

Second Hand Connecting Rod of CAT Engine

At RA Power Solutions, we specialize in precision inspection and repair of connecting rods for marine engines, power plants, and industrial diesel engines.

Why is connecting rod inspection important?

A damaged or worn-out connecting rod can lead to serious engine problems such as:

Excessive vibration
Piston seizure
Crankshaft damage
Catastrophic engine failure

To avoid these issues, thorough inspection and repair should be part of every engine overhaul and maintenance schedule.

Our Inspection Process Includes:

1. Visual Inspection:

We look for visible cracks, discoloration due to overheating, and wear patterns.

2. Dimensional Check:

Using micrometers, bore gauges, and other precision tools, we check:
Big end bore diameter
Small end bore diameter
Overall length
Parallelism and twist

3. Crack Detection (NDT Testing):

We use Magnetic Particle Inspection (MPI) or Ultrasonic Testing (UT) to detect internal or surface-level cracks invisible to the naked eye.

4. Hardness Testing:

This helps determine whether the connecting rod material is still within acceptable strength limits after long-term usage.

5. Bolt and Bush Inspection:

We thoroughly inspect or replace the connecting rod bolts and bushes, which are often prone to fatigue and wear.

Industries We Serve

We serve a diverse client base in Asia, Africa, the Middle East, and Latin America, including marine, power generating, mining, cement, and heavy engineering industries.

Connecting Rod Of Daihatsu Ready For Dispatch — Connecting Rod ready for dispatch

Need Expert Inspection Services?

With over 45 years of experience, RA Power Solutions is your trusted partner for connecting rod inspection and repair. We provide services both on-site and in-house, ensuring minimum downtime and maximum quality.

For more information regarding engine connecting rods, used connecting rods, connecting rod inspection, engine block repair, please email us at rajshahani@rapowersolutions.com or info@rapowersolutions.com, or call us at +91 9582647131 or +91 9810012383.

Frequently Asked Questions (FAQs):

1. How often should connecting rods be inspected?

It is recommended to inspect connecting rods during every major engine overhaul or after every 10,000–15,000 hours of operation, depending on engine type.

2. What are the signs of a faulty connecting rod?

Excessive noise, engine knocking, vibration, and poor engine performance can indicate a problem with the connecting rod.

3. Can a cracked connecting rod be repaired?

Minor cracks can sometimes be repaired using certified welding and heat treatment. However, replacement is advised if the integrity is compromised.

4. Do you offer on-site connecting rod inspection?

Yes, RA Power Solutions specializes in on-site inspection and repair of connecting rods and other engine components globally.

5. What industries typically need connecting rod services?

We serve marine, power plants, cement, mining, oil & gas, and heavy industries with high-capacity engines.

The connecting rod is an important component of engine operation. It connects the piston to the crankshaft, converting the piston’s linear action into rotational motion. Over time and with continuous engine use, the connecting rod experiences high amounts of tension and wear. This makes routine inspection and maintenance of the connecting rod essential to ensure … Continue reading “Connecting Rod Inspection – A Critical Step in Engine Overhaul By RA Power Solutions”